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Blue Giant U-Series Installation & Owner's Manual

Air cylinder dock leveler with blue genius control station
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U-SERIES AIR CYLINDER DOCK LEVELER
with BLUE GENIUS
TM
DO NOT INSTALL, OPERATE OR SERVICE THIS PRODUCT UNLESS YOU HAVE READ AND
FULLY UNDERSTAND THE ENTIRE CONTENTS OF THIS MANUAL. FAILURE TO DO SO MAY
RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH.
U-Series Air Cylinder Dock Leveler with Blue Genius
CONTROL STATION
INSTALLATION &
OWNER'S MANUAL
Applies to Serial No. 378109 and up
BLUE GENIUS
WARNING
TM
Controls. Issue Date: June 11, 2013. Rev.7 (Part#038-750E)
SERIES
TM

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Summary of Contents for Blue Giant U-Series

  • Page 1 FULLY UNDERSTAND THE ENTIRE CONTENTS OF THIS MANUAL. FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH. U-Series Air Cylinder Dock Leveler with Blue Genius Controls. Issue Date: June 11, 2013. Rev.7 (Part#038-750E) Applies to Serial No. 378109 and up...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS ABOUT THE U-SERIES AIR CYLINDER DOCK LEVELER with BLUE GENIUS CONTROLS......1.1 Owner’s Purchase Record............................INTRODUCTION ................................. 2.1 Warranty Information............................. 2.1 Exclusion of Liability.............................. 2.2 Manufacturer's Note.............................. OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION..............3.1 Operational Safety Warnings..........................

  • Page 3: About The U-Series Air Cylinder Dock Leveler With Blue Genius

    ABOUT the U-SERIES AIR CYLINDER DOCK LEVELER with BLUE GENIUS CONTROLS The U-Series Air Cylinder dock leveler harnesses the power of air to deliver the same heavy-duty, proven performance that makes Blue Giant dock levelers a standard at loading docks worldwide.

  • Page 4: Introduction

    WARRANTY INFORMATION Thank you for purchasing Blue Giant products. We appreciate your business, and are confident that our product will serve you for many years to come. In the event that you experience a problem with our product, our Warranty Center is here to support the Blue Giant Product(s) that you have purchased.

  • Page 5: Operator's Manual Safety Message Color Identification

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATOR’S MANUAL SAFETY MESSAGE COLOR IDENTIFICATION This manual includes color-coded safety messages that clarify instructions and specify areas where potential hazard exists. To prevent the possibility of equipment damage and serious injury or death, please observe strictly the instructions and warnings contained in the messages.

  • Page 6: Lockout / Tagout Procedure And Rules

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS LOCKOUT / TAGOUT PROCEDURE and RULES In accordance with the rules and regulations of the Occupational  Safety and Health Administration (OSHA), all affected employees must be notified that the machine or equipment will...

  • Page 7: Standalone Dock Arrangement

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS STANDALONE DOCK ARRANGEMENT NEW CONSTRUCTION: 1. DRILL ONE HOLE THROUGH THE WALL TO THE OUTSIDE FOR THE L.E.D COMMUNICATION LIGHTS (OPTIONAL). BLUE GENIUS CONTROL STATION 2. RUN ONE 1/2” I.D. CONDUIT FROM CONTROL STATION TO THE REMOTE I/O BOX (MOUNTED &...

  • Page 8: Weld Installation Pictorial

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS WELD INSTALLATION PICTORIAL WELD INSTALLATION PICTORIAL (Shim placement guidance only- dock depicted may not be same model covered in this manual) FORK LIFT TRUCK HANDLING SLING HANDLING STITCH WELD 1/4" 6”...

  • Page 9: Dock Leveler Installation Instructions

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DOCK LEVELER INSTALLATION INSTRUCTIONS  WIDTH Do not install, operate and/or service this leveler until you LENGTH have read and understood all of the safety information and instructions contained herein and on the leveler.

  • Page 10: Installation Inspection

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DOCK LEVELER INSTALLATION INSTRUCTIONS  REAR FRAME UPPER REAR Do not work beneath the dock leveler without engaging the PIT ANGLE maintenance strut. Do not work beneath the dock leveler without following proper lockout procedures.

  • Page 11: Electrical Installation

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS ELECTRICAL INSTALLATION  DO NOT WIRE HIGH AND LOW VOLTAGES IN THE SAME CONDUIT. High voltage range is 115V and up. Lower voltages include the communication and solenoid wiring as well as the I/O.

  • Page 12: Control Station Operation

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS CONTROL STATION OPERATION CONTROL STATION TYPE - Independent Hydraulic or Air Cylinder Dock Leveler Blue Genius SCROLL ‘UP’ ESCAPE MENU SCREEN SELECT SCROLL ‘DOWN’ RED LIGHT (Do Not Enter) Do Not Enter...

  • Page 13: Operating Instructions

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS WARNING WARNING Do not operate this leveler unless you have been trained Secure the transport vehicle with a vehicle restraint, wheel chocks or other method before commencing traffic across the dock leveler.

  • Page 14: Storing The Dock Leveler

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS MENU DISPLAY SCREEN: MENU DISPLAY SCREEN: L i p M o v i n g D e c k R a i s i n g e n iu s...

  • Page 15: Returning To Normal Lip On Load Bed Operation

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS OPERATING INSTRUCTIONS MENU DISPLAY SCREEN: D e c k R a i s i n g e n iu s ES C lu e SE L En ter Do No t...

  • Page 16: Maintenance

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS MAINTENANCE   The Maintenance strut must be in place before commencing Do not operate and/or service this dock leveler until you have read maintenance procedures. and understood all of the safety information and instructions contained herein and on the dock leveler.

  • Page 17: Pm Checklist

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS 11.7 PM CHECK LIST - ACU DOCK LEVELER P M C H E C K L I S T – DOCK EQUIPMENT Customer S W O # Location Cust. Contact Date...

  • Page 18: General Assembly Components - 6' Docks

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS 12A. GENERAL DOCK ASSEMBLY COMPONENTS- 6’ DOCKS Item No. Qty. Part No. Description Item No. Qty. Part No. Description 26-011067 FRAME WELD 72” 012-200 REGULAR SPRING LOCK WASHERS 26-003947 DECK WELD...

  • Page 19: General Assembly Components - 8' Docks

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS 12B. GENERAL DOCK ASSEMBLY COMPONENTS- 8’ DOCKS Item No. Qty. Part No. Description Item No. Qty. Part No. Description 26-011070 FRAME WELD 72” 011-502 HEX NUTS (U.S.) 26-005761 DECK WELD 010-006 CAP SCREW 5/16-18 X 1 HH GR.

  • Page 20: General Assembly Components - 10' Docks

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS 12C. GENERAL DOCK ASSEMBLY COMPONENTS- 10’ DOCKS Item No. Qty. Part No. Description Item No. Qty. Part No. Description 26-011074 FRAME WELD 72” 010-006 CAP SCREW 5/16-18 X 1 HH GR. 5 ZC...

  • Page 21: Air Cylinder Motor Assembly

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS AIR CYLINDER MOTOR ASSEMBLY Item No. Qty. Part No. Description Item No. Qty. Part No. Description 26-009937 MASTER ENCLOSURE BOX 010-001 CAP SCREW ¼-20 X 1 HH 009980-1 VALVES ASSEMBLY 011-545 NYLON INSERT LOCKNUTS ¼”-20 (U.S.)

  • Page 22: Lip Cylinder Assembly

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS LIP CYLINDER ASSEMBLY 1/2" 1" 13/16" 20.18 TO 21.79 Item No. Qty. Part No. Description 114-663 CLEVIS 26-005734 MUFFLER ½” NPT 034-509 REDUCER 26-007667 MALE CONNECTOR 26-003945-2 CLEVIS WELDMENT 010-227 H.H.C.S. 12MM X 20MM...

  • Page 23: Deck Cylinder Assembly- 6' And 7' Docks

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DECK CYLINDER ASSEMBLY- 6’ and 7’ DOCKS 5 1/4" 2" 1.005 1.000 BOTH ENDS 2 1/16" 24 1/8" TO 38 5/8" Item No. Qty. Part No. Description 26-005847-1 REAR CLEVIS WELDMENT 010-227 H.H.C.S.

  • Page 24: Deck Cylinder Assembly- 8' Docks

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DECK CYLINDER ASSEMBLY- 8’ DOCKS 7" 2" 30.125 " TO 46.625" 1.005 1.000 2 1/4" Item No. Qty. Part No. Description 26-005847-6 REAR CLEVIS WELDMENT 010-230 HEX HEAD CAP SCREWS 012-221...

  • Page 25: Deck Cylinder Assembly- 10' Docks

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS DECK CYLINDER ASSEMBLY- 10’ DOCKS 5 1/4" 2" 1.005 1.000 BOTH ENDS 2 1/16" 27.6" TO 45.6" Item No. Qty. Part No. Description 26-005847-1 REAR CLEVIS WELDMENT 012-220 REGULAR SPRING LOCK WASHERS 010-227 H.H.C.S.

  • Page 26: Fall-Safe Assembly

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS FALL-SAFE ASSEMBLY Item No. Qty. Part No. Description 26-008709 CYLINDER ASSEMBLY 034-580 3/8 MALE ORING TO FEMALE PIPE 034-515 FITTING 034-793 VELOCITY FUSE 035-231 28-008964 23-003569 034-674 FITTING 26-010153 TUBE 26-009935...

  • Page 27: Safety Side Skirts

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS SAFETY SIDE SKIRTS SIDE SAFETY SKIRTS ITEM QTY PART NO. DESCRIPTION ITEM QTY PART NO. DESCRIPTION ------- ------- 202-5024 Safety Skirt Package - 6’ & 8’ Long 011-135 Capscrew, Sckt Butn/Hd 5/16”-18x3/4 202-0036 Safety Skirt, Lower - 6’...

  • Page 28: Recommended Spare Parts

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS RECOMMENDED SPARE PARTS * Complements for Fall Safe Cylinder* Part # Description Qty Req'd **HARDWARE REQ'D:** 26-008709 CYLINDER ASS'Y 1 1/2" BORE X 22" STR. Qty: 1, Part # 26-008964 Pin & Qty: 1, Part # 23-003569 Pin...

  • Page 29: Recommended Spare Parts For Blue Genius Gold Series I

    U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS RECOMMENDED SPARE PARTS- BLUE GENIUS GOLD SERIES I Single Phase: Part # Description Qty Req'd 026-PB1115-FH POWER BOARD SUBASSY (1PH 115V 50-60HZ) 026-PB1230-FH POWER BOARD SUBASSY (1PH 230V 50-60HZ) Three Phase:...
  • Page 30 U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS NOTES...
  • Page 31 U-SERIES AIR CYLINDER DOCK LEVELER WITH BLUE GENIUS™ CONTROLS NOTES...
  • Page 32 Corporate 85 Heart Lake Road South USA 6350 Burnt Poplar Road Brampton, ON, Canada L6W 3K2 Greensboro, NC 27409 t 905.457.3900 f 905.457.2313 www.BlueGiant.com If calling within North America: t 1.800.668.7078 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2013...

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